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EBB 342Quality Management & Control
A s s o c . P r o f . I r . D r . C h e o n g K u a n Ye w
S c h o o l o f M a t e r i a l s & M i n e r a l R e s o u r c e s E n g i n e e r i n g
E n g i n e e r i n g C a m p u s
U n i v e r s i t i S a i n s M a l a y s i a
EBB 342 Quality Management & Control
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Please Take Note
Purpose of OBE
Course Structure
Teaching Schedule
Group AssignmentInvited Talk
Test
Attandance
Lecture Notes
What to cover?
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What to Cover?
Introduction to Quality Management & ControlManagement Aspect of Quality
ISO 9000 SeriesProblem Solving
Quality Planning & AnalysisFocusing on Customers
Introduction to Statistical InferenceIntroduction to Design of Experiment
Sampling TechniquesIntroduction to Reliability
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Are youready to start?
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Introduction toQuality Management & Control
A s s o c . P r o f . I r . D r . C h e o n g K u a n Ye w
S c h o o l o f M a t e r i a l s & M i n e r a l R e s o u r c e s E n g i n e e r i n g
E n g i n e e r i n g C a m p u s
U n i v e r s i t i S a i n s M a l a y s i a
EBB 342 Quality Management & Control
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Topic Outcomes
1. Define and discuss (a) quality and (b) quality
management
2.Explain the importance of quality
improvement.
3.Discuss the different dimensions of quality.
4.Discuss the evolution of modern quality
improvement methods.
5.Discuss the role that variability and statistical
methods play in controlling and improving
quality.
At the end of this lecture, students will be able to:
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Topic Outline
Introduction
Meaning of Quality & Management.
Quality Engineering Terminology.
Evolutionary Development of Quality Control & Improvement.
Statistical Methods for Quality Control & Improvement.
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Introduction
You are buying a loaf of bread for your breakfast. Thereare variety brands of bread in the market. How do youdecide which brand of bread to buy?
How can you make sure that the bread is safe toconsume?
Do you think you may use the same criteria to select thebread if it is not for you own consumption?
If the criteria are different, explain why.
Do you think your personal attitude and monetory statuscan influence your decision?
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What had you learnt?
Characteristics / criteria
Decision making
Attitude – personal value, feeling
Technical / Specification & Safety AspectMonetory vs Quality
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Meaning of Quality & Management
What is Quality Management?
Quality Manage
ment
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Bridging
People &
TechnicalRequirement.
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What is quality?
The term quality has developed over time.
Various interpretations.
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Examples:
Bread, Hand phone, World University Ranking.
Simple definition:
It is one of the most important factors for consumer to
selectselect a product (decision making criteria).
It is related to the desired characteristicsdesired characteristics of a
product.
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Meaning of Product
(1) Manufactured goods
Car, computer, hand phone, pen, table, etc.
(2) Services
Public transport, banking, telephone services, internet
provider services, educational services, etc.
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Judgmental Perspective (Transcendent quality) –
superiority/excellent (Rolex, BMW)
Product-based Perspective
User-based Perspective (Nissan – Datsun)
Value-based Perspective (usefulness/satisfaction – price)
Manufacturing-based Perspective (conformance to spec.)
Integrating Perspectives on Quality
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Quality Perspective in the Value Chain
Transcendentquality
&Product-based
quality
User-basedquality
Value-basedquality
Manufacturing- basedquality
Marketing
Design
ManufacturingDistribution
needs
Information flow
Product flow
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17The quality of a product can be evaluated in
several ways using Garvin’s (1987) 8dimensions of quality .
“Competing in eight dimensions of quality – Harvard Business Review [Sept-
Oct, 87(6), pp. 101-109]”
Quality is a multifaceted entity
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8
Dimensionsof
Quality
Performancehe product do the intended job?)
Reliability (how often does the product fail?)
Durability (how long does the produ
Serviceability Serviceability asy is it to repair the product?)
Aesthetics(what does the product look
Featurest does the product do?)
Perceived Quality putation of the company or its product?) Conformance to Standa
(is the product made exactly as the desig
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Definition of QUALITY
K. Ishikawa:quality of work, quality of service, quality of quality of work, quality of service, quality of
information, quality of process, quality of information, quality of process, quality of
division, quality of people, including division, quality of people, including workers, engineers, managers, and workers, engineers, managers, and
executives, quality of system, quality of executives, quality of system, quality of company, quality of objectives, etc.company, quality of objectives, etc.
A.V. Feigenbaum:Total customer satisfactionTotal customer satisfaction,
including attractiveness, reliability, serviceability,and maintainability.
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•Fitness for useFitness for use[Fitness is defined by customer]
•Degree of excellence(products must meet the requirement of the user
Actual Quality)
Joseph .M. JuranJoseph .M. Juran
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Philip B. CrosbyPhilip B. Crosby
“Conformance to requirements.” [requirements may not fully represent what
customer wants]
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Noriaki Kano et al.Noriaki Kano et al.
Quality has two dimensions:(1)Must-be quality [near to “fitness for use” Actual Quality]
(2)Attractive quality [what a customer would love
Perceive Quality]
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American Society for Quality (ASQ):
•A subjective term for which each person has
his or her own definition.
•In technical usage, quality can have two
meanings:
•characteristics of a product or service
that bear on its ability to satisfy stated
or implied needs.
•product or service free of deficiencies.
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Stated: Technical requirements.
Implied: Not explicitly known
requirements; to be ensured by
procedures & qualifications.
Deficiencies:Deficiencies: No disturbance of supply chainNo disturbance of supply chain
and no fail in application.and no fail in application.
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ISO 8402
The totality of features
and characteristics of aproduct or service that bears
on its ability to satisfy statedand implied needs.
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Quality is inversely proportional to variability(unwanted or harmful variability)
iabilityvar
1
Qualityα
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Variability
Distribution of measured critical
characteristics.
Shifted from target.
Out of specification band.
Within specification band.
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Specification Band
TargetLower Spec. Limit
(LSL)Upper Spec. Limit
(USL)
M e a
s ur e d D a t a
A
B
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Quality RM/$
Variability Repair & warranty claims Rework
Waste time, effort, money
Cheaper production cost
Profit
Why do we need to reduce variability?
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Reduction of variability in processes and
products
Identify sources of variable Quality improvement methodology
Quality improvement:
The reduction of variability in
processes and products
How do we reduce variability?
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ExcellentJust nice
Quality
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Two general aspects
Quality of Conformance
Quality of Design
•Lack of formal education
•Less focus
•Conformance-to-standards
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ManagementManagement
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What is “Management”? What is “Management”?
•Mary Parker Follet (1868 – 1933):
•The art of getting things donethrough PEOPLE.
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“action of measuring a quality on a
regular basis and of adjusting some
initial plan”
or
“the actions taken to reach one’sintended goal.”
Function of Management
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5 functions:
•Planning•Organizing
•Leading
•Coordinating
•Controlling
Henri Fayol:
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AttitudeRIGHT
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Importance of Organizational Structure
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Quality Management
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Quality Management
Quality Manage
ment
•
Set up and run a quality system to ensure conformanceto stated and implicit requirements and reach nodeficiencies.
•Get this done through your people.
•Set up and run a quality system to ensure conformanceto stated and implicit requirements and reach no
deficiencies.•Get this done through your people.
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Quality Engineering Terminology
(1) Quality characteristics (critical-to-quality, CTQ)
what are the elements users think of the quality of a product?
Garvin’s dimensions of quality.
2 scenarios
It is important to select characteristics that can be used to
represent the product quality
World university ranking
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42Physical(length, weight, voltage)
Sensory(appearance, color)
Time Orientation(reliability, durability, serviceability)
Manufactured Goods
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43Physical
(Staff student ratio, lab,
facility)
Conformance to standard(BEM, EAC, Washington Accord)
Performance
(citations, R&D,consultancy)
Aesthetics
(Campus location,surrounding)
Sensory/Perceived
Quality(peer review,
employer review,student review)
Service
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(2) Quality Engineering
A set of operational, managerial, and
engineering activities that a company uses to ensure that the quality
characteristics of a product are at a
nominal or required levels.
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(3) Statistical method
Tools to control and improve quality.
Classify data on quality characteristics as: Attributes (discrete measurements)
Variables (continuous measurements)
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(4) Specification Quality characteristics are often evaluated relative to
specification.
Requirement
Nominal (target) value,
Upper spec. limit (USL)
Lower spec. limit (LSL) – optional.
The results of engineering design process for a
product.
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(5) Nonconforming Products that fail to meet one or more of its
specification.
defective
(6) nonconformity
A specific type of failure
defect
A nonconforming productnot necessarily unfit for use
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48Evolutionary Development of Quality
Control and Improvement Extracted from:
D. C. Montgomery, Introduction to Statistical Quality Control, 5th ed, Wiley, 2005, pp. 9-10.
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oIndividual craftsman.
oStandardized interchangeable parts.
oDivide work into smaller & more easily accomplished units.
o Assembly line; mistake-proof assembly concept;
self-checking, and in-process inspection (Ford).
o1st Standard Lab (UK).
oSystematic inspection/testing (AT&T).
oSupplier certification program.
oTechnical Inspection Assoc. (England).
o
Quality Dept. (AT&T Bell lab)oStatistical methods to control quality of electric
lamps (GE).
oDoE in Agricultural sciences.
oControl Chart concepts (Bell Lab).
1887
1900s
1907
1920s
1924
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o Acceptance sampling method.
oMinistry of Supply Advising Service on Statistical
Methods & QC (UK)oThe American Society for QC (ASQC).
oISO
oTotal Quality Control (Feignbanm)
oJuran & Gryna (Quality Control Handbook).
oQC circle concept (Ishikawa).
oNational Council for Quality & Productivity (UK).
oZero Defects (ZD) program.
oISO 1st quality systems standard.
oMalcolm Balbridge National Quality Award.
oMotorola’s six sigma initiative.
oSPC/QC courses in Engineering syllabus.
o American Society for Quality (ASQ).
1928
1946
1951
1957
1998
1960
1960s
1987
1989
1995
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DoE
ZD
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Statistical MethodsforQuality Control & Improvement
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53Statistical Methods for Quality Control
& Improvement
Measurement: assessment & metrics
3 major areas: Statistical Process Control (SPC)
Statistical Inference & Design of Experiments
Acceptance Sampling
Objective: Systematic reduction of variability .
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(1) SPC
PROCESS
INPUT(raw materials,
components,subassemblies)
OUTPUT PRODUCT
•Measurement•Evaluation•Monitoring &•Control
…..
…..
Controllable inputs
x1 x2 xpx3
z1 z2 z3zp
Uncontrollable inputs
Process Monitoring Technique•Control Chart•Others SPC techniques
Corrective action & Reduced variability
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(2) Design of Experiments
Techniques to discover the key variables influencing
the quality characteristics of interest in the process.
An approach to systematically varying the controllable
input factors in the process and determining the
effect these factors have on the output product
parameters.
Reducing variability Optimizing process performance.
Obtain significant breakthrough in process
performance.
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56Factorial design
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Off-line quality control tool
Often used during development activities and early
stages of manufacturing
SPC on-line (in-process)
Identify a list of important input variables
Output quality characteristicsmodel
DOE,regression analysis, etc.
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(3) Acceptance Sampling (AS)
Closely connected with inspection and testing
of product.
One of the earliest QC.
The inspection and classification of a sample of units selected at random from a larger batch andthe ultimate decision about disposition of the lot.
Modern QA system less emphasize on AS
more effort in SPC and DOE
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Typical evolution in the use of these techniques.
AcceptanceSampling
Process Control
Design of Experiments
0
100
% of Application
TimeMaturity
Phase diagram of the use of quality-engineering methods
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Application of quality-engineering techniques and the systematicreduction of process variability
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Effective monitoring & surveillance of a Process
On-line ProcessControl Tools
(SPC)
Acti it
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Activity
Develop yourDevelop your
own personalown personalquality quality
checklist.checklist.
Suggested standards for a personal quality
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S gg p q ychecklist. (Quality Is Personal: A foundation for Total Quality
Management, 1993)
•Review class notes after each class.•Limit phone calls.
•No more than 10 h of TV per week.
•Get up promptly.
•Complete all reading assignment as due.•Plan by using a breif outline of what is to be accomplished
daily.
•Refer to daily plan each day.
•Stick to one subject at a time while studying.
•Don’t doggedly persist in trying to clear up confusing point.
•Don’t spend too much time on routine activities.
•In bed every night before midnight.
•
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Reflection
End of Topic
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